Optical beam scanning apparatus, method of manufacturing optical beam scanning apparatus, image forming apparatus and method of manufacturing image forming apparatus

ABSTRACT

In an image forming apparatus according to the invention, an optical beam scanning apparatus of an overillumination scanning optical system includes a laser, a pre-deflection optical system, a polygon mirror, and a post-deflection optical system, wherein the post-deflection optical system includes at least one optical element configured by allowing a resin to flow into a molding die through a gate opening provided in advance to the molding die and then molding the resin into a prescribed shape; and in the optical element, a side corresponding to a side of the gate opening through which the resin flows is provided to a light incidence side where the luminous flux enters into the polygon mirror.

BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

The present invention relates to an optical beam scanning apparatus anda method of manufacturing an optical beam scanning apparatus and to animage forming apparatus provided with this optical scanning apparatusand a method of manufacturing an image forming apparatus. In particular,the invention relates to an optical beam scanning apparatus which in anoverillumination scanning optical system in which a width of a luminousflux made incident on a polygon mirror is wider than a width of onereflecting surface forming the polygon mirror, is capable of scanningthe luminous flux on a photoconductive drum and a method ofmanufacturing an optical beam scanning apparatus and to an image formingapparatus provided with this optical beam scanning apparatus and amethod of manufacturing an image forming apparatus.

2. Related Art

In recent years, in image forming apparatus of an electrophotographicmode, for example, laser printers, digital copiers and laser facsimiles,an optical beam scanning apparatus for irradiating laser light (opticalbeam) on a surface of a photoconductive drum and scanning the laserlight to form an electrostatic latent image on the photoconductive drumis provided.

Recently, in order to devise to realize high-speed scanning on a surfaceof a photoconductive drum, for example, a method in which plural lightsources (laser diodes) are provided in one laser unit, therebyincreasing the number of laser light per one scanning (multibeam method)is proposed. In this multibeam method, plural beams for every colorcomponent emitted from each of light sources (for example, yellow,magenta, cyan, and black) are processed in a pre-deflection opticalsystem and converted into one beam, which is then made incident on apolygon mirror. The beam deflected by the polygon mirror is mediatedthrough an fθ lens configuring a post-deflection optical system andsubsequently separated into a beam for every color component andirradiated on a photoconductive drum of every color component.

Here, the rotation axis direction of the polygon mirror as a deflectoris defined as “sub-scanning direction”, and a direction vertical to eachof the optical axis direction of the optical system and the rotationaxis direction of the deflector (polygonal mirror) is defined as “mainscanning direction”. Incidentally, the sub-scanning direction in theoptical system is corresponding to a conveyance direction of a transfermaterial in an image forming apparatus, and the main scanning directionin the optical system is corresponding to a direction vertical to theconveyance direction within a surface of the transfer material in theimage forming apparatus. Also, an image surface shows the surface of thephotoconductive drum, and an imaging surface shows a surface on which aluminous flux (laser light) actually forms an image.

In general, a relation expressed by [Expression 1] is present among animage processing rate (paper conveyance rate), an image resolution, amotor rotation rate and a number of polygon mirror surfaces.

$\begin{matrix}{{P*R} = \frac{25.4*{Vr}*N}{60}} & \left\lbrack {{Expression}\mspace{14mu} 1} \right\rbrack\end{matrix}$

In the foregoing expression, P (mm/s) represents a processing rate(paper conveyance rate); and R (dpi) represents an image resolution(number of dots per inch). Also, Vr (rpm) represents a number ofrevolutions of a polygon motor; and N represents a number of polygonmirror surfaces.

As expressed by the foregoing [Expression 1], the printing speed andresolution in the image forming apparatus are proportional to the numberof revolutions of a polygon motor (Vr) and the number of polygon mirrorsurfaces (N). Accordingly, in order to realize high resolution as wellas high speed in the image forming apparatus, it is necessary toincrease the number of polygon mirror surfaces (N) or to raise thenumber of revolutions of the polygon motor (Vr).

However, in a conventional general underillumination scanning opticalsystem, a width of a luminous flux (laser light) made incident on apolygon mirror in a main scanning direction is made smaller than a widthof one reflecting surface forming the polygon mirror in the mainscanning direction (reflection width) thereby reflecting the whole ofthe luminous flux (laser light) made incident on the polygon mirror.

However, since not only a beam diameter on the image surface isproportional to an F number, but also the F number Fn is expressed byFn=f/D wherein f represents a focal distance of the imaging opticalsystem, and D represents a beam diameter of the main scanning directionon the polygon mirror surface, when it is intended to make the beamdiameter on the image surface small for the purpose of devising torealize high image quality, the beam diameter of the main scanningdirection on the polygon mirror surface must be made large.

In other words, in order to obtain high image quality at a certain levelor more, there is a restriction that the beam diameter of the mainscanning direction on the polygon mirror surface must be regulated to afixed size or more.

Nevertheless, in order to realize high resolution as well as high speed,when it is intended to increase the number of polygon mirror surfaces(N), the polygon mirror itself must be increased in size. As a result,when it is intended to rotate a large-sized polygon mirror at a highspeed, a load to a motor for driving the polygon mirror becomes large,and the motor cost increases. In addition, at the same time, the noiseor vibration of the motor or the generation of a heat becomes large, anda countermeasure thereto becomes necessary separately.

Then, an image forming apparatus using an overillumination scanningoptical system is proposed in place of the underillumination scanningoptical system. In the overillumination scanning optical system, a widthof a luminous flux made incident on a polygon mirror is made wider thana width of one reflecting surface forming the polygon mirror.

According to this, it is possible to reflect the luminous flux by usingthe entire surface of the reflecting surface forming the polygon mirror(or plural reflecting surfaces); and even in the case where it isintended to ensure the beam diameter on the polygon mirror surface whileincreasing the number of reflecting surfaces of polygon mirror (N) forthe purpose of devising to realize high resolution as well as highspeed, it is possible to make the diameter of the polygon mirror itselfsmall. Accordingly, a load to a motor for driving the polygon mirror canbe reduced, and the motor cost can be reduced. Also, since not only thediameter of the polygon mirror itself can be made small, but also thenumber of reflecting surfaces can be increased, it is possible to makethe shape of the polygon mirror close to a circle, and it is possible tomake the air resistance at the time of driving the polygon mirror low.As a result, even when the polygon mirror is rotated in a high speed, itis possible to reduce the noise or vibration and the generation of aheat.

Furthermore, following the reduction in the noise or vibration and thegeneration of heat, the whole or a part of countermeasures element forreducing the noise or vibration, such as glasses, become unnecessary,and the costs in manufacturing an image forming apparatus can belowered. Also, a high duty cycle becomes possible.

The foregoing overillumination scanning optical system is described in,for example, Leo Beiser, Laser Scanning Notebook, SPIE OPTICALENGINEERING PRESS.

In the case where an imaging lens is manufactured by using a resin as amaterial of an imaging lens included in a post-deflection optical systemand molding the resin into a prescribed shape, gate cutting becomesnecessary. But, a residual stain or deformation is generated in thevicinity of the gate cut part of the manufactured imaging lens due to aheat at the time of gate cutting.

For example, in the case where the lens of a post-deflection opticalsystem is a molded lens which is manufactured by molding a resin whichhas been allowed to flow into a molding die through a side gate opening,a residual strain or deformation or the like is generated in an end ofthe imaging lens in the side corresponding to the side of the gateopening or the like due to a heat at the time of gate cutting.

When a luminous flux (laser light) passes through a gate cut part of thelens in which a residual strain or deformation or the like has beengenerated due to a heat at the time of such gate cutting, the beamdiameter on the image surface becomes large as compared with the usual.

In particular, in the case where the lens of a post-deflection opticalsystem is configured of a single lens, since the lens requires a largerpower, it is necessary that the lens is a thick-wall lens. For thatreason, the cross-sectional area of the lens to be molded in thevicinity of the side gate opening for making a resin flow therein (gatecut part of the lens) becomes large so that when it is intended to gatecut this portion, a residual strain or deformation is more likelygenerated in the lens due to a heat at the time of gate cutting. As aresult, when a luminous flux (laser light) passes through the gate cutpart of the lens, the beam diameter on the image surface becomes largeras compared with the usual.

Here, in the conventional underillumination scanning optical system, awidth of a laser beam L deflected by the polygon mirror corresponding tothe main scanning direction was constant irrespective of the scanningposition (angle). However, in the overillumination scanning opticalsystem, the width of the laser beam L corresponding to the main scanningdirection fluctuates depending upon the scanning position (angle).

Concretely, in the case where the optical axis of the laser beam L madeincident on the polygon mirror and the optical axis of thepost-deflection optical system form an angle, the width of the luminousflux corresponding to the main scanning direction fluctuates dependingupon the scanning position (angle).

For that reason, the F number varies depending upon the scanningposition (angle); and when the laser beam is made incident on thepolygon mirror, as it goes from a light incidence side to an oppositeside to the light incidence side, the beam diameter of the main scanningdirection on the image surface becomes large, thereby generatingscattering in beam diameter of the main scanning direction on the imagesurface. In other words, the beam diameter of the main scanningdirection on the image surface is bilaterally asymmetric against theoptical axis of the optical system in a scanning region on thephotoconductive drum; and when the laser beam L is made incident on thepolygon mirror, as it goes from a light incidence side to an oppositeside to the light incidence side, the optical characteristics on theimage surface become worse.

For that reason, in the case of manufacturing an imaging lens by moldinga resin, when the side gate is used, if the gate cut part of the imaginglens is arranged in the opposite side to the light incidence side, inthe opposite side to the light incidence side, in addition to theworseness of optical characteristics on the image surface, the beamdiameter on the image surface becomes very large due to influences of aresidual strain or deformation generated at the time of gate cutting.

As a result, scattering in the beam diameter in a scanning region of thephotoconductive drum as an image surface becomes large.

SUMMARY OF THE INVENTION

The present invention was made in the view of the circumstancesencouraged in the prior art mentioned above, and it is an object of thepresent invention to provide an optical beam scanning apparatus whicheven in the case where a residual strain or deformation is generated atthe time of lens molding, is able to not only reduce scattering in abeam diameter in a scanning region but also prevent the deterioration ofimage quality and a method of manufacturing an optical beam scanningapparatus, and an image forming apparatus provided with this opticalbeam scanning apparatus and a method of manufacturing an image formingapparatus.

In order to solve the foregoing problems, an optical beam scanningapparatus according to an aspect of the invention is an optical beamscanning apparatus including a light source for emitting a luminousflux, a pre-deflection optical system for forming a luminous fluxemitted from the light source to image the luminous flux as a line imagein a prescribed direction corresponding to a main scanning direction, ascanning unit configured to scan the imaged luminous flux by thepre-deflection optical system against a scanning subject, and apost-deflection optical system for imaging the luminous flux scanned bythe scanning unit on the scanning subject, in which a width of theluminous flux made incident on the scanning unit from the pre-deflectionoptical system is wider than a width of one reflecting surface formingthe scanning unit and an angle formed by an optical axis of the luminousflux made incident on the scanning unit and an optical axis of thepost-deflection optical system is satisfied with a prescribed condition,wherein the post-deflection optical system includes at least one opticalelement configured by allowing a resin to flow into a molding diethrough a gate opening provided in advance to the molding die and thenmolding the resin into a prescribed shape; and in the optical element, aside corresponding to a side of the gate opening through which the resinflows is provided to a light incidence side where the luminous fluxenters into the scanning unit.

In order to solve the foregoing problems, a method of manufacturing anoptical beam scanning apparatus according to an aspect of the inventionis a method of manufacturing of an optical beam scanning apparatusincluding a light source for emitting a luminous flux, a pre-deflectionoptical system for forming a luminous flux emitted from the light sourceto image the luminous flux as a line image in a prescribed directioncorresponding to a main scanning direction, a scanning unit configuredto scan the imaged luminous flux by the pre-deflection optical systemagainst a scanning subject, and a post-deflection optical system forimaging the luminous flux scanned by the scanning unit on the scanningsubject, in which a width of the luminous flux made incident on thescanning unit from the pre-deflection optical system is wider than awidth of one reflecting surface forming the scanning unit and an angleformed by an optical axis of the luminous flux made incident on thescanning unit and an optical axis of the post-deflection optical systemis satisfied with a prescribed condition, wherein after allowing a resinto flow into a molding die through a gate opening for allowing a resinto flow into the molding die, which is provided in advance to themolding die, the flown-in resin is molded into a prescribed shape tomanufacture an optical element; and in arranging at least one opticalelement in the post-deflection optical system, the optical element isarranged such that a side corresponding to a side of the gate openingthrough which the resin flows is a light incidence side where theluminous flux enters into the scanning unit.

In order to solve the foregoing problems, an image forming apparatusaccording to an aspect of the invention is an image forming apparatusprovided with an optical beam scanning apparatus including a lightsource for emitting a luminous flux, a pre-deflection optical system forforming a luminous flux emitted from the light source to image theluminous flux as a line image in a prescribed direction corresponding toa main scanning direction, a scanning unit configured to scan the imagedluminous flux by the pre-deflection optical system against a scanningsubject, and a post-deflection optical system for imaging the luminousflux scanned by the scanning unit on the scanning subject, in which awidth of the luminous flux made incident on the scanning unit from thepre-deflection optical system is wider than a width of one reflectingsurface forming the scanning unit and an angle formed by an optical axisof the luminous flux made incident on the scanning unit and an opticalaxis of the post-deflection optical system is satisfied with aprescribed condition, wherein the post-deflection optical systemincludes at least one optical element configured by allowing a resin toflow into a molding die through a gate opening provided in advance tothe molding die and then molding the resin into a prescribed shape; andin the optical element, a side corresponding to a side of the gateopening through which the resin flows is provided to a light incidenceside where the luminous flux enters into on the scanning unit.

In order to solve the foregoing problems, a method of manufacturing animage forming apparatus according to an aspect of the invention is amethod of manufacturing of an image forming apparatus provided with anoptical beam scanning apparatus including a light source for emitting aluminous flux, a pre-deflection optical system for forming a luminousflux emitted from the light source to image the luminous flux as a lineimage in a prescribed direction corresponding to a main scanningdirection, a scanning unit configured to scan the imaged luminous fluxby the pre-deflection optical system against a scanning subject, and apost-deflection optical system for imaging the luminous flux scanned bythe scanning unit on the scanning subject, in which a width of theluminous flux made incident on the scanning unit from the pre-deflectionoptical system is wider than a width of one reflecting surface formingthe scanning unit and an angle formed by an optical axis of the luminousflux made incident on the scanning unit and an optical axis of thepost-deflection optical system is satisfied with a prescribed condition,wherein after allowing a resin to flow into a molding die through a gateopening for allowing a resin to flow into the molding die, which isprovided in advance to the molding die, the flown-in resin is moldedinto a prescribed shape to manufacture an optical element; and inarranging at least one optical element in the post-deflection opticalsystem, the optical element is arranged such that a side correspondingto a side of the gate opening through which the resin flows is a lightincidence side where the luminous flux enters into the scanning unit.

In the optical beam scanning apparatus according to an aspect of theinvention, in the optical beam scanning apparatus including a lightsource for emitting a luminous flux, a pre-deflection optical system forforming a luminous flux emitted from the light source to image theluminous flux as a line image in a prescribed direction corresponding toa main scanning direction, a scanning unit configured to scan the imagedluminous flux by the pre-deflection optical system against a scanningsubject, and a post-deflection optical system for imaging the luminousflux scanned by the scanning unit on the scanning subject, in which awidth of the luminous flux made incident on the scanning unit from thepre-deflection optical system is wider than a width of one reflectingsurface forming the scanning unit and an angle formed by an optical axisof the luminous flux made incident on the scanning unit and an opticalaxis of the post-deflection optical system is satisfied with aprescribed condition, the post-deflection optical system includes atleast one optical element configured by allowing a resin to flow into amolding die from a gate opening provided in advance to the molding dieand then molding the resin into a prescribed shape; and in the opticalelement, a side corresponding to a side of the gate opening throughwhich the resin flows is provided to a light incidence side where theluminous flux enters into the scanning unit.

In the method of manufacturing an optical beam scanning apparatusaccording to an aspect of the invention, in the method of manufacturingof an optical beam scanning apparatus including a light source foremitting a luminous flux, a pre-deflection optical system for forming aluminous flux emitted from the light source to image the luminous fluxas a line image in a prescribed direction corresponding to a mainscanning direction, a scanning unit configured to scan the imagedluminous flux by the pre-deflection optical system against a scanningsubject, and a post-deflection optical system for imaging the luminousflux scanned by the scanning unit on the scanning subject, in which awidth of the luminous flux made incident on the scanning unit from thepre-deflection optical system is wider than a width of one reflectingsurface forming the scanning unit and an angle formed by an optical axisof the luminous flux made incident on the scanning unit and an opticalaxis of the post-deflection optical system is satisfied with aprescribed condition, after allowing a resin to flow into a molding diethrough a gate opening for allowing a resin to flow into the moldingdie, which is provided in advance in the molding die, the flown-in resinis molded into a prescribed shape to manufacture an optical element; andin arranging at least one optical element in the post-deflection opticalsystem, the optical element is arranged such that a side correspondingto a side of the gate opening through which the resin flows is a lightincidence side where the luminous flux enters into the scanning unit.

In the image forming apparatus according to an aspect of the invention,in image forming apparatus provided with an optical beam scanningapparatus including a light source for emitting a luminous flux, apre-deflection optical system for forming a luminous flux emitted fromthe light source to image the luminous flux as a line image in aprescribed direction corresponding to a main scanning direction, ascanning unit configured to scan the imaged luminous flux by thepre-deflection optical system against a scanning subject, and apost-deflection optical system for imaging the luminous flux scanned bythe scanning unit on the scanning subject, in which a width of theluminous flux made incident on the scanning unit from the pre-deflectionoptical system is wider than a width of one reflecting surface formingthe scanning unit and an angle formed by an optical axis of the luminousflux made incident on the scanning unit and an optical axis of thepost-deflection optical system is satisfied with a prescribed condition,the post-deflection optical system includes at least one optical elementconfigured by allowing a resin to flow into the molding die through agate opening provided in advance to the molding die and then molding theresin into a prescribed shape; and in the optical element, a sidecorresponding to a side of the gate opening through which the resinflows is provided to a light incidence side where the luminous flux madeenters into the scanning unit.

In the method of manufacturing an image forming apparatus according toan aspect of the invention, in the method of manufacturing of an imageforming apparatus provided with an optical beam scanning apparatusincluding a light source for emitting a luminous flux, a pre-deflectionoptical system for forming a luminous flux emitted from the light sourceto image the luminous flux as a line image in a prescribed directioncorresponding to a main scanning direction, a scanning unit configuredto scan the imaged luminous flux by the pre-deflection optical systemagainst a scanning subject, and a post-deflection optical system forimaging the luminous flux scanned by the scanning unit on the scanningsubject, in which a width of the luminous flux made incident on thescanning unit from the pre-deflection optical system is wider than awidth of one reflecting surface forming the scanning unit and an angleformed by an optical axis of the luminous flux made incident on thescanning unit and an optical axis of the post-deflection optical systemis satisfied with a prescribed condition, after allowing a resin to flowinto a molding die through a gate opening for allowing a resin to flowinto the molding die, which is provided in advance to the molding die,the flown-in resin is molded into a prescribed shape to manufacture anoptical element; and in arranging at least one optical element in thepost-deflection optical system, the optical element is arranged suchthat a side corresponding to a side of the gate opening through whichthe resin flows is a light incidence side where the luminous flux entersinto the scanning unit.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings,

FIG. 1 is a view to show a configuration of an image forming apparatusprovided with an optical beam scanning apparatus according to theinvention;

FIG. 2 is a view to show a detailed configuration of the optical beamscanning apparatus of FIG. 1;

FIG. 3 is a view to show an outline configuration of the inside of acontrol system of an image forming apparatus provided with the opticalbeam scanning apparatus of FIG. 2;

FIG. 4 is a diagram to show respective factors of a surface shape of animaging lens;

FIG. 5 is an explanatory view to explain an imaging lens including asurface having a diffraction surface;

FIG. 6 is an explanatory view to explain other imaging lens including asurface having a diffraction surface;

FIG. 7 is an explanatory view to explain an imaging lens where onlycurvatures of a lens are arranged;

FIG. 8 is an explanatory view to explain other imaging lens including asurface having a diffraction surface;

FIG. 9 is an explanatory view to explain an imaging lens of a centralgate where a gate cut position is arranged in a central part on a bottomsurface of an imaging lens;

FIG. 10 is a diagram to show respective factors of a surface shape ofthe imaging lens of FIG. 9;

FIG. 11 is a view to show a detailed configuration of an optical beamscanning apparatus in the case of using the imaging lens of FIG. 9;

FIG. 12 is a diagram to show a relation between a distance from a gatecut position to an effective region and a beam diameter in the case ofan imaging lens of a central gate;

FIG. 13 is an explanatory view to explain a residual strain ordeformation or the like due to a heat at the time of gate cutting asgenerated in an imaging lens 61;

FIG. 14 is a view to show a relation between a scanning angle of apolygon mirror and a reflecting beam diameter; and

FIG. 15 is a view to show a detailed configuration of an optical beamscanning apparatus in the case a gate cut part of an imaging lens isarranged in a light incidence side.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the invention are hereunder described with reference tothe drawings.

FIG. 1 shows a configuration of an image forming apparatus 1 providedwith an optical beam scanning apparatus 21 according to the invention.

As illustrated in FIG. 1, the image forming apparatus 1 includes, forexample, a scanner section 10 as an image reading unit and a printersection 20 as an image forming unit.

The scanner section 10 has a first carriage 11 formed movably into anarrow direction; a second carriage 12 to be moved following the firstcarriage 11; an optical lens 13 for imparting a prescribed imagingcharacteristic to light from the second carriage 12; a photoelectricconversion device 14 for not only photoelectrically converting the lightto which a prescribed imaging characteristic has been imparted by theoptical lens 13 but outputting an electric signal after thephotoelectric conversion; an original table 15 for holding an originalD; an original fixing cover 16 for fixing the original D by pressing itonto the original table 15, and the like.

The first carriage 11 is provided with a light source 17 forilluminating the original D and a mirror 18 a for reflecting catoptriclight reflected from the original D upon illumination with light emittedfrom the light source 17 towards the second carriage 12.

The second carriage 12 has a mirror 18 b for bending light guided fromthe mirror 18 a of the first carriage 11 by 90° and a mirror 18 c forfurther bending the light which has been bent by the mirror 18 b by 90°.

The original D placed on the original table 15 is illuminated by thelight source 17, thereby reflecting catoptric light where light andshade of light corresponding to the presence or absence of an image isdistributed. This catoptric light due to the original D is made incidentand guided as image information of the original D into the optical lens13 via the mirrors 18 a, 18 b and 18 c.

The catoptric light guided into the optical lens 13 from the original Dis collected on a light-receiving surface of the photoelectricconversion device (for example, a CCD sensor) 14 by the optical lens 13.

Then, when an indication to start the image formation is inputted from anon-illustrated operation panel or external apparatus, the firstcarriage 11 and the second carriage 12 are once moved to a home positionwhich is determined in advance so as to have a prescribed positionalrelation to the original table 15 by drive of a non-illustrated carriagedriving motor.

Thereafter, when the first carriage 11 and the second carriage 12 aremoved along the original table 15 at a prescribed rate, not only theimage information of the original D, namely the catoptric light (imagelight) reflected from the original D is cut out in a prescribed widthalong a direction where the mirror 18 a is extended, namely a mainscanning direction and reflected towards the mirror 18 b, but thecatoptric light reflected from the original D is successively taken outin units of a width cut out from the mirror 18 a with respect to adirection orthogonal to the direction where the mirror 18 a is extended,namely a sub-scanning direction. According to this, all the imageinformation of the original D is guided into the photoelectricconversion device 14. Incidentally, an electric signal outputted fromthe photoelectric conversion device 14 is an analogue signal and isconverted into a digital signal by a non-illustrated A/D converter andtemporarily stored as an image signal in a non-illustrated image memory.

Thus, the image of the original D placed on the original table 15 isconverted into a digital image signal of, for example, 8 bits exhibitinglight and shade of an image in a non-illustrated image processingsection for every one line along the first direction where the mirror 18a is extended by the photoelectric conversion device 14.

The printer section 20 has the optical beam apparatus 21 as an exposureapparatus as explained later by referring to FIG. 2 and FIG. 3 and animage forming section 22 of an electrophotographic mode capable offorming an image on recording paper P as a medium on which an image isformed.

The image forming section 22 is rotated by a main motor 23A such that anouter peripheral surface is moved at a prescribed rate as explained byreferring to FIG. 3. The image forming section 22 has a drum-likephotoconductor (hereinafter referred to as “photoconductive drum”) 23 onwhich an electrostatic latent image is formed corresponding to an imagedata, namely the image of the original D upon irradiation with a laserbeam (laser light) L from the optical beam scanning apparatus 21; acharging apparatus 24 for giving a surface potential of a prescribedpolarity to a surface of the photoconductive drum 23; a developmentapparatus 25 for selectively feeding a toner as a visualizing materialto the electrostatic latent image on the photoconductive drum 23 formedby the optical beam scanning apparatus and developing it; a transferapparatus 26 for giving a prescribed electric field to a toner imageformed on the outer periphery of the photoconductive drum 23 by thedevelopment apparatus 25 and transferring it onto the recording paper P;a separation apparatus 27 for releasing the recording paper P onto whichthe toner image has been transferred by the transfer apparatus 26 andthe toner between the recording paper P and the photoconductive drum 23from electrostatic adsorption with the photoconductive drum 23 andseparating them from the photoconductive drum 23; and a cleaningapparatus 28 for removing the transfer residual toner remaining on theouter peripheral surface of the photoconductive drum 23 and returningthe potential distribution of the photoconductive drum 23 to a statebefore the surface potential is fed by the charging apparatus 24; andthe like.

Incidentally, the charging apparatus 24, the development apparatus 25,the transfer apparatus 26, the separation apparatus 27 and the cleaningapparatus 28 are disposed in this order along an arrow direction inwhich the photoconductor drum 23 is rotated. Also, the laser beam L fromthe optical beam scanning apparatus 21 is irradiated in a prescribedposition X on the photoconductive drum 23 between the charging apparatus24 and the development apparatus 25.

In a non-illustrated image processing section, an image signal read fromthe original D in the scanner section 10 is not only converted into aprinting signal by processing, for example, contour correction orgradation processing for half tone display but converted into a lasermodulation signal for changing a light intensity of the laser beam Lemitted from a semiconductor laser device (semiconductor laser device 41of FIG. 2) of the optical beam scanning apparatus 21 as described laterto any one of an intensity at which an electrostatic latent image can berecorded on the outer periphery of the photoconductive drum 23 to whicha prescribed surface potential is given by the charging apparatus 24 oran intensity at which the latent image is not recorded.

Each semiconductor laser device (semiconductor laser device 41 of FIG.2) provided in the optical beam scanning apparatus 21 is subjected tointensity modulation based on the foregoing laser modulation signal andemits light so as to record an electrostatic latent image in aprescribed position of the photoconductive drum 23 corresponding to aprescribed image data. This laser light from the semiconductor laserdevice is deflected in a first direction which is the same direction asa reading line of the scanner section 10 by a deflector (polygon mirror50 as a deflector of FIG. 2) within the optical beam scanning apparatus21 and irradiated in the prescribed position X on the outer periphery ofthe photoconductive drum 23.

Then, when the photoconductive drum 23 is rotated in the arrow directionat a prescribed rate, similar to the movement of the fist carriage 11and the second carriage 12 of the scanner section 10 along the originaltable 7, a laser beam from the semiconductor laser device which issuccessively deflected by the deflector (polygon mirror 50 as adeflector of FIG. 2) within the optical beam scanning apparatus 21 isexposed at prescribed intervals on the outer periphery of thephotoconductive drum 23 for every one line.

An electrostatic latent image corresponding to the image signal is thusformed on the outer periphery of the photoconductive drum 23.

The electrostatic latent image formed on the outer periphery of thephotoconductive drum 23 is developed with a toner from the developmentapparatus 25. A toner image developed with the toner is not onlyconveyed to a position opposing to the transfer apparatus 26 due to therotation of the photoconductive drum 23 but transferred onto therecording paper P which is fed by taking out a single sheet thereof froma paper cassette 29 by a paper feed roller 30 and a separation roller 31and then adjusting the timing by aligning rollers 32, due to an electricfield from the transfer apparatus 26.

The recording paper P onto which the toner image has been transferred isseparated together with the toner by the separation apparatus 27 andguided into a fixation apparatus 34 by a conveyance apparatus 33.

The recording paper P guided into the fixation apparatus 34 is subjectedto fixation of the toner (toner image) due to a heat and a pressure fromthe fixation apparatus 34 and then discharged into a tray 36 by paperdischarge rollers 35.

On the other hand, the photoconductive drum 23 in which the toner image(toner) has been transferred onto the recording paper P by the transferapparatus 26 is made opposed to the cleaning apparatus 28 due to thesubsequent continuous rotation. Then, the transfer residual toner(residual toner) remaining on the outer peripheral surface of thephotoconductive drum 23 is removed by the cleaning apparatus 28.Furthermore, the photoconductive drum 23 is returned to an initial statewhich is a state before feeding a surface potential by the chargingapparatus 24. According to this, next image formation becomes possible.

By repeating the foregoing process, a continuous image forming actionbecomes possible.

Thus, when the image information is read in the scanner section 10 andthe read image information is converted into a toner image in theprinter section 20 and outputted onto the recording paper P, theoriginal D set on the original table 15 is copied.

Incidentally, while the foregoing image forming apparatus 1 has beenapplied to a digital copier or the like, it is not limited to such case.For example, it may be applied to a printer apparatus in which an imagereading section is not present or the like.

FIG. 2( a) and FIG. 2( b) each shows a detailed configuration of theoptical beam scanning apparatus 21 of FIG. 1. Incidentally, FIG. 2( a)is an outline plan view in the case where plural optical elementsdisposed between a light source (semiconductor laser device 41) includedin the optical beam scanning apparatus 21 and the photoconductive drum23 (defined as “scanning subject”) are viewed from an orthogonaldirection (sub-scanning direction) to a main scanning direction which isa parallel direction to a direction in which laser light going from thepolygon mirror 50 as a deflector towards the photoconductive drum 23 isscanned by the polygon mirror 50. FIG. 2( b) is an outlinecross-sectional view of the optical beam scanning apparatus 21 on anX-X′ line of FIG. 2( a).

As illustrated in FIG. 2( a) and FIG. 2( b), the optical beam scanningapparatus 21 has a pre-deflection optical system 40 having thesemiconductor laser device 41 for emitting the laser beam (laser light)L of, for example, 658 nm; a collimation lens 42 for converting across-sectional beam shape of the laser beam L emitted from thesemiconductor laser device 41 into convergent light or parallel light ordivergent light; an aperture 43 for controlling the quantity of light(luminous flux width) of the laser beam L which has passed through thecollimation lens 42 to a prescribed size; a cylindrical lens 44 which isgiven a positive power only in the sub-scanning direction for thepurpose of arranging the cross-sectional shape of the laser beam L, thequantity of light of which has been controlled by the aperture 43, intoa prescribed cross-sectional beam shape; a mirror 45 for bending thelaser beam L from the semiconductor laser device 41, which has beenarranged into a prescribed cross-sectional beam shape by a finite focallens or the collimation lens 42, the aperture 43 and the cylindricallens 44, in a prescribed direction; and the like.

The polygon mirror 50 integrally formed with a polygon mirror motor 50Arotating at a prescribed rate is provided in a direction where the laserbeam L to which a prescribed cross-sectional beam shape has been givenby the pre-deflection optical system 40 advances. The polygon mirror 50scans the laser beam L, the cross-sectional beam shape of which has beenarranged into a prescribed shape by the cylindrical lens 44, towards thephotoconductive drum 23 positioned at a later stage.

A post-deflection optical system 60 for imaging the laser beam L whichis continuously reflected on each of reflecting surfaces of the polygonmirror 50 in a generally straight line along an axis direction of thephotoconductive drum 23 is provided between the polygon mirror 50 andthe photoconductive drum 23.

The post-deflection optical system 60 is composed of an imaging lens(generally called as “fθ lens”) 61; a dustproof glass 62 for preventingturnaround of the toner, dusts or paper powder or the like floatingwithin the image forming section 22 into a non-illustrated housing ofthe optical beam scanning apparatus 21; and the like. The imaging lens61 is able to irradiate the laser beam L continuously reflected on theindividual reflecting surfaces of the polygon mirror 50 from one end tothe other end of the longitudinal (axis) direction of thephotoconductive drum 23 in the exposing position X as illustrated inFIG. 1 while making the position on the photoconductive drum 23proportional to a rotation angle of each of the reflecting surfaces ofthe polygon mirror 50 upon irradiation on the photoconductive drum 23and also to provide convergence properties to which a prescribedrelation based on an angle at which the polygon mirror 50 is rotated soas to have a prescribed cross-sectional beam diameter in any position ofthe longitudinal direction on the photoconductive drum 23.

Incidentally, an optical path of the laser beam L from the semiconductorlaser device 41 within the optical beam scanning apparatus 21 to thephotoconductive drum 23 is bent within a non-illustrated housing of theoptical beam scanning apparatus 21 by non-illustrated plural mirrors orthe like. Also, the imaging lens 61 and at least one non-illustratedmirror may be integrally formed in advance by optimizing curvatures ofthe imaging lens 61 in the main scanning direction and the sub-scanningdirection and an optical path between the polygon mirror 50 and thephotoconductive drum 23.

Also, in the optical beam scanning apparatus 21 as illustrated in FIG.2( a) and FIG. 2( b), when an axis O_(I) along a principal ray of thelaser beam L made incident on each of the reflecting surfaces of thepolygon mirror 50 and an optical axis O_(R) of the post-deflectionoptical system 60 are each projected on a main scanning plane on thephotoconductive drum 23, an angle α formed by the both is 5°, whereas ascanning angle β of a half-image region is 26°. Also, in the opticalbeam scanning apparatus 21 as illustrated in FIG. 2( a) and FIG. 2( b),an angle formed by the laser beam L made incident and the optical axisO_(R) of the post-deflection optical system 60 is 2°.

Next, FIG. 3 shows an outline configuration of the inside of a controlsystem of the image forming apparatus 1 including the optical beamscanning apparatus 21 as illustrated in FIG. 2( a) and FIG. 2( b).

A CPU (central processing unit) 101 as a main control apparatus isconnected with a ROM (read only memory) 102 storing a prescribedoperation rule or initial data; a RAM (random access memory) 103 fortemporarily storing an inputted control data, a result of arithmeticprocessing by the CPU 101, or the like; an image RAM 104 for not onlyholding an image data from the photoelectric conversion device 14 or animage data fed from an external apparatus but outputting an image datato an image processing circuit 106; an NVM (non-volatile memory) 105 forholding a data which has been stored so far even in the case whereelectricity to the image forming apparatus 1 is blocked due to batterybackup; the image processing circuit 106 for subjecting the image datastored in the image RAM 104 to prescribed image processing, therebyoutputting a laser driver 121; and the like.

Also, the CPU 101 is connected with the laser driver 121 for making thesemiconductor laser device 41 of the optical beam scanning apparatus 21emit light; a polygon motor driver 122 for driving the polygon motor 50Afor rotating the polygon mirror 50; a main motor driver 123 for drivingthe main motor 23A for driving the photoconductive drum 23, a conveyancemechanism of the recording paper P or the like; and the like.

In the optical beam scanning apparatus 21, the divergent laser beam Lemitted from the semiconductor laser device 41 is converted intoconvergent light, parallel light or divergent light with respect to thecross-sectional beam shape by the lens 42.

The laser beam L, the cross-sectional beam shape of which has beenconverted into a prescribed shape, passes through the aperture 43,whereby not only the luminous flux width and the quantity of light areoptimally set up, but prescribed convergence properties are given onlyin the sub-scanning direction by the cylindrical lens 44. According tothis, the laser beam L becomes linear (line image) extending in the mainscanning direction on each of the reflecting surfaces of the polygonmirror 50.

The polygon mirror 50 is, for example, a regular dodecahedron and isformed so as to have an inscribed circle diameter Dp of about 25 mm.When the number of reflecting surfaces of the polygon mirror 50 isdefined as N, a width Wp of the main scanning direction of each of thereflecting surfaces (12 surfaces) of the polygon mirror 50 can bedetermined as expressed by [Expression 2].

Wp=tan(π/N)×Dp  [Expression 2]

In the case of the embodiment of the invention, the width Wp of the mainscanning direction of each of the reflecting surfaces (12 surfaces) ofthe polygon mirror 50 is Wp=tan(π/12)×25=6.70 mm.

On the other hand, a beam width D_(L) of the main scanning direction ofthe laser beam L irradiated on each of the reflecting surfaces of thepolygon mirror 50 is generally 32 mm and is set up widely as comparedwith the width Wp=6.70 mm of the main scanning direction of theindividual reflecting surfaces of the polygon mirror 50. By setting upthe beam width D_(L) of the main scanning direction of the laser beam Lwidely in the main scanning direction, it is possible to reducescattering in the quantity of light between the scanning end and thescanning center on the image surface (photoconductive drum 23).

The laser beam L which has been scanned (deflected) in a straight lineupon being guided onto each of the reflecting surfaces of the polygonmirror 50 and then continuously reflected due to the rotation of thepolygon mirror 50 is imparted a prescribed imaging characteristic by theimaging lens 61 of the post-deflection optical system 60 such that thecross-sectional beam diameter is generally uniform in at least the mainscanning direction on the photoconductive drum 23 (image surface) andimaged in a generally straight line on the surface of thephotoconductive drum 23.

Also, the rotation angle of the individual reflecting surfaces of thepolygon mirror 50 and the scanning position (imaging position) of thelight beam imaged on the photoconductive drum 23 are corrected by theimaging lens 61 so as to have a proportional relation with each other.Accordingly, the speed of the light beam which is scanned in a straightline on the photoconductive drum 23 becomes constant over the entirescanning region by the imaging lens 61. Incidentally, in the imaginglens 61, the respective reflecting surfaces of the polygon mirror 50 areindividually non-parallel to the sub-scanning direction, namely acurvature (curvature of the sub-scanning direction) capable ofcorrecting a deviation of the scanning position in the sub-scanningdirection due to an influence caused by the generation of inclination oneach of the reflecting surfaces is imparted. Furthermore, an imagesurface curve of the sub-scanning direction is corrected, too. In orderto correct these optical characteristics, the curvature of thesub-scanning direction is changed by the scanning position.

The shape of the lens surface of the imaging lens 61 has numericalvalues as shown in, for example, FIG. 4 and is defined according to[Expression 3].

$\begin{matrix}{X = {\frac{{{CUY}*y^{2}} + {{CUZ}*z^{2}}}{1 + \sqrt{1 - {{AY}*{CUY}^{2}*y^{2}} - {{AZ}*{CUZ}^{2}*z^{2}}}} + {\sum\limits_{n = 0}{\sum\limits_{m = 0}{A_{mn}y^{m}z^{2n}}}}}} & \left\lbrack {{Expression}\mspace{14mu} 3} \right\rbrack\end{matrix}$

By using such imaging lens 61, the rotation angle θ of the individualreflecting surfaces of the polygon mirror 50 and the position of thelaser beam L to be imaged on the photoconductive drum 23 are madegenerally proportional to each other, it is possible to correct theposition when the laser beam L is imaged on the photoconductive drum 23.

Also, the imaging lens 61 is able to correct a deviation of theinclination of the sub-scanning direction of the mutual respectivereflecting surfaces of the polygon mirror 50, namely a deviation of theposition of the sub-scanning direction caused due to scattering in theamount of surface inclination.

Concretely, by making the laser beam incident surface (the side of thepolygon mirror 50) and the emitting surface (the side of thephotoconductive drum 23) of the imaging lens 61 have a generally opticalconjugated relation, even in the case where an inclination definedbetween an arbitrary reflecting surface of the polygon mirror 50 and therotation axis of the polygon mirror 50 defers in every reflectingsurface, it is possible to correct a deviation of the scanning positionof the sub-scanning direction of the laser beam L guided onto thephotoconductive drum 23.

Incidentally, since the cross-sectional beam diameter of the laser beamL replies upon a wavelength of the light beam L emitted from thesemiconductor laser device 41, when the wavelength of the laser beam Lis set up at 785 nm, it is possible to make the cross-sectional beamdiameter of the laser beam L large. Also, by setting up the wavelengthat 630 nm or shorter, it is possible to make the cross-sectional beamdiameter of the laser beam L smaller.

The reflection mirror after the deflection is configured of a planesurface, and correction of the surface inclination is performed only bythe imaging lens 61.

As a matter of course, the surface shape of the imaging lens 61 may be,for example, a toric lens having a rotation symmetrical axis to the mainscanning axis and having a varied curvature of the sub-scanningdirection depending upon the scanning position. According to this, arefractive power of the sub-scanning direction varies depending upon thescanning position, and a scanning line curvature can be corrected.Furthermore, in the case where the curved surface of the sub-scanningdirection has a rotation symmetrical axis, a degree of freedom of thecurvature of the sub-scanning direction is widened, and it is possibleto achieve the correction more precisely.

Here, for example, as in an imaging lens 66 as illustrated in FIGS. 5(a) and 5(b), the imaging lens 61 which is included in thepost-deflection optical system 60 may include a surface having adiffraction surface (diffraction optical device). According to this, theinfluence due to an environmental fluctuation can be reduced.Incidentally, in the case of the imaging lens 66 as illustrated in FIGS.5( a) and 5(b), the diffraction surface is provided only in a side ofthe emitting surface, but the diffraction surface may be provided in aside of the incident surface or on the both surfaces. As a matter ofcourse, the same is also applicable in the case where plural imaginglenses are configured. Also, not only the imaging lens but other opticaldevice may be provided.

Also, in general, for example, as in an imaging lens 67 as illustratedin FIGS. 6( a) and 6(b), the diffraction surface is provided on a planesurface. But, for example, as in the imaging lens 66 as illustrated inFIGS. 5( a) and 5(b), by imparting it to a surface with a power, it ispossible to reduce the number of lenses. Furthermore, by bringing apower by a diffraction optical device, it is possible to reduce afluctuation in the wall thickness or to make the wall thickness thin;and it is possible to improve the productivity and the precision and toreduce the cost due to shortening of a molding time.

That is, for example, as illustrated in FIG. 7, by arranging onlycurvatures of lens having a power of the conventional imaging lens 61,it is possible to reduce a fluctuation in the wall thickness and to makethe wall thickness thin while having a lens action. According to this,as in an imaging lens 68 as illustrated in FIG. 8, the fluctuation inthe wall thickness of lens can be reduced. Also, in the case whereplural optical devices after the deflection are configured, the numberof optical devices can be reduced.

Incidentally, a non-illustrated horizontal synchronous sensor isprovided in an opposite side to the polygon mirror 50.

Now, in the case of manufacturing the imaging lens 61 by using a resinas a material of the imaging lens 61, making the resin flow in from agate opening provided in advance in a molding die and then molding theresin into a prescribed shape, it is necessary to perform gate cuttingin the gate opening side of the imaging lens 61 after molding the resin.But, a residual strain or deformation is generated in a sidecorresponding to the gate opening side of the manufactured imaging lens61, namely in the vicinity of the gate cut part due to a heat at thetime of gate cutting.

Then, first of all, the residual strain or deformation generated in thevicinity of the gate cut part of the imaging lens 61 of a central gatein the case where the gate cut position for performing gate cutting isarranged in a central part of the bottom of the imaging lens 61 isdescribed.

FIGS. 9( a) to 9(d) each shows the imaging lens 61 of a central gatewhere the gate cut position is arranged in the central part of thebottom of the imaging lens 61. Incidentally, FIG. 9( a) is a plan viewof the imaging lens 61; and FIG. 9( b) is a view seen from a Y directionof FIG. 9( a). FIG. 9( c) is a side view of FIG. 9( b); and FIG. 9( d)is a plan view in the case where the imaging lens 61 of FIG. 9( a) isseen from a direction of the bottom.

Here, when a length in the longitudinal direction and a length in theray advancing direction (optical axis direction) of the gate opening aredefined as “I” and “m”, respectively, for example, I=60 mm and m=4 mm.

The shape of the lens surface of the imaging lens 61 as illustrated inFIGS. 9( a) to 9(d) has numerical values as shown in, for example, FIG.10 and is defined according to [Expression 3]. A material of thisimaging lens 61 is a methyl methacrylate resin (PMMA: polymethylmethacrylate). The “effective region” as referred to herein is definedas a region where the laser beam L as catoptric light reflected from thepolygon mirror 50 effectively passes through the imaging lens 61 andforms an image on the photoconductive drum 23.

A configuration of the optical beam scanning apparatus 21 using thisimaging lens 61 is illustrated in FIG. 11. At this time, an inscribedcircle diameter Dp of the polygon mirror 50 is 29 mm.

Next, FIG. 12 shows a relation between a distance from a gate cutposition to an effective region and a beam diameter in the case of theimaging lens of 61 of a central gate.

As shown in FIG. 12, when the distance from the gate cut position to theeffective region is short, the beam diameter becomes large with respectto the beam diameter of 60 μm as a designed value. This means that whenthe distance from the gate cut position to the effective region isshort, the optical characteristics of the effective region areinfluenced. In particular, in the case of the imaging lens 61 of acentral gate, the range on the effective region influenced by a heat atthe time gate cutting becomes large, and of the effective region, aregion influencing the optical characteristics becomes large.

Accordingly, in the case of manufacturing the imaging lens 61 by makinga resin flow in from a gate opening provided in advance in a molding dieand then molding the resin, it is desirable that the manufacture iscarried out in a side gate rather than a central gate. Also, for thepurpose of minimizing the influence against the optical characteristicsof the effective region, when it is intended to make the distance fromthe gate cut position to the effective region long, it is necessary thata molding die in which the resin is made to flow is increased in size,leading to an increase of the molding die cost. Furthermore, a moldingmachine with a large clamping force becomes necessary. Thus, it isbetter that the distance between the gate cut position and the effectiveregion is short.

Then, in the case of manufacturing the imaging lens 61 by making a resinflow in from a gate opening provided in advance in a molding die andthen molding the resin, a side gate is used. But, even by using a sidegate, a residual strain or deformation or the like is generated in anend of the imaging lens 61 in the side corresponding to the gate openingside in which the resin is made to flow or the like due to a heat at thetime of gate cutting.

Concretely, in the case where the imaging lens 61 of the post-deflectionoptical system 60 is a molded lens manufactured by molding a resin whichhas been made to flow in from the side gate opening, for example, asillustrated in FIGS. 13( a) and 13(b), a residual strain or deformationor the like is still generated in a lens in a side corresponding to thegate opening side (in particular, an end of lens or the like) due to aheat at the time of gate cutting. Incidentally, FIG. 13( b) is a viewseen from a Z direction of FIG. 13( a).

When a luminous flux (laser light) passes through the gate cut part ofthe imaging lens 61 in which such a residual strain or deformation orthe like has been generated due to a heat at the time of gate cutting,the beam diameter on the image surface becomes larger than the usual.

In particular, in the case where the imaging lens 61 of thepost-deflection optical system 60 is configured of a single lens, sincethe imaging lens 61 is required to have a larger power, it must befinished as a wall-thick lens. For that reason, the cross-sectional areaof the imaging lens 61 (gate cut part of the imaging lens 61) which ismolded in the vicinity of the side gate opening for making a resin flowin becomes large so that when it is intended to gate cut this portion, aresidual strain or deformation is still more likely generated in theimaging lens 61 due to a heat at the time of gate cutting. As a result,when a luminous flux (laser light) passes through the gate cut part ofthe imaging lens 61, the beam diameter on the image surface still morebecomes large as compared with the usual.

Here, in the overillumination scanning optical system, a width of thelaser beam L corresponding to the main scanning direction variesdepending upon the scanning position (angle).

Concretely, for example, as illustrated in FIG. 14, in the case wherethe optical axis of the laser beam L made incident on the polygon mirror50 and the optical axis of the post-deflection optical system form anangle, a width of the luminous flux corresponding to the main scanningdirection varies by the scanning position (angle).

That is, a width in a light incidence side (a) when the laser beam L ismade incident on the polygon mirror 50, a central position (b) of thescanning region of the photoconductive drum 23 and an opposite side (c)to the light incidence side (width of the laser beam L corresponding tothe main scanning direction) is Da, Db and Dc, respectively, and thesewidths become small in the order of Da>Db>Dc. For that reason, the Fnumber varies depending upon the scanning position (angle) and the beamdiameter of the main scanning direction on the image surface isproportional to the F number; and when the laser beam L is made incidenton the polygon mirror 50, as it goes from the light incidence side (a)to the opposite side (c) to the light incidence side, the beam diameterof the main scanning direction on the image surface becomes large,thereby generating scattering in beam diameter of the main scanningdirection on the image surface (photoconductive drum 23). In otherwords, the beam diameter of the main scanning direction on the imagesurface (photoconductive drum 23) is bilaterally asymmetric against theoptical axis of the optical system in the scanning region on thephotoconductive drum 23; and when the laser beam L is made incident onthe polygon mirror 50, as it goes from the light incidence side (a) tothe opposite side (c) to the light incidence side, the opticalcharacteristics on the image surface become worse.

For that reason, in the case of manufacturing the imaging lens 61 bymaking a resin flow in from the gate opening and then molding the resin,when a side gate is used, if the gate cut part of the imaging lens 61 isarranged in the opposite side to the light incidence side, in theopposite side to the light incidence side, in addition to the worsenessof optical characteristics on the image surface (photoconductive drum23), the beam diameter on the image surface (photoconductive drum 23)becomes very large due to influences of a residual strain or deformationgenerated at the time of gate cutting.

As a result, scattering in the beam diameter in the scanning region ofthe photoconductive drum 23 as an image surface becomes large.

Then, for example, as illustrated in FIG. 15, a gate cut part of theimaging lens 61 is arranged in the light incidence side (namely, a sidecorresponding to the gate opening side of the imaging lens 61).According to this, not only the matter that in the opposite side to thelight incidence side, the beam diameter on the image surface(photoconductive drum 23) becomes very large due to the influences of aresidual strain or deformation generated at the time of gate cutting inaddition to the worseness of optical characteristics on the imagesurface can be prevented, but the scattering in the beam diameter in thescanning region on the photoconductive drum 23 can be reduced and madeuniform.

Accordingly, even in the case where a residual strain or deformation isgenerated at the time of forming a lens, not only it is possible toreduce the scattering in the beam diameter in the scanning region, butit is possible to prevent the deterioration of image quality and todevise to realize high image quality. Also, it is possible to reduce themanufacturing cost of the image forming apparatus 1.

Incidentally, as a matter of course, the invention is also applicable toimaging lenses including a surface having a diffraction surface(diffraction optical device) (for example, imaging lens 66 to 68explained with reference to FIGS. 5 to 8).

Furthermore, the number of a luminous flux from the light source may beone or plural.

1. An optical beam scanning apparatus comprising: a light source foremitting one or plural luminous fluxes, a pre-deflection optical systemto form a luminous flux emitted from the light source to image theluminous flux as a line image in a prescribed direction corresponding toa main scanning direction, a scanning unit configured to scan the imagedluminous flux by the pre-deflection optical system against a scanningsubject, and a post-deflection optical system to image the luminous fluxscanned by the scanning unit on the scanning subject, in which a widthof the luminous flux made incident on the scanning unit from thepre-deflection optical system is wider than a width of one reflectingsurface forming the scanning unit and an angle formed by an optical axisof the luminous flux made incident on the scanning unit and an opticalaxis of the post-deflection optical system is satisfied with aprescribed condition, wherein the post-deflection optical systemincludes at least one optical element configured by allowing a resin toflow into a molding die through a gate opening provided in advance tothe molding die and then molding the resin into a prescribed shape; andin the optical element, a side corresponding to a side of the gateopening through which the resin flows is provided to a light incidenceside where the luminous flux enters into the scanning unit.
 2. Theoptical beam scanning apparatus according to claim 1, wherein theoptical element is a lens.
 3. The optical beam scanning apparatusaccording to claim 1, wherein the optical element is configured of asingle lens.
 4. The optical beam scanning apparatus according to claim1, wherein the post-deflection optical system includes plural opticalelements configured by allowing the resin to flow into the molding diethrough the gate opening and then molding the resin into a prescribedshape; and with respect to at least one optical element of the pluraloptical elements, in the optical element, a side corresponding to a sideof the gate opening through which the resin flows is provided to a lightincidence side where the luminous flux enters into the scanning unit. 5.The optical beam scanning apparatus according to claim 4, wherein withrespect to all of the optical elements of the plural optical elements,in the optical element, a side corresponding to a side of the gateopening through which the resin flows is provided in a light incidenceside enters into the luminous flux made incident on the scanning unit.6. The optical beam scanning apparatus according to claim 1, wherein inthe optical element, a gate cut part of the optical element is includedin a side corresponding to the side of the gate opening through whichthe resin flows.
 7. The optical beam scanning apparatus according toclaim 1, wherein at least one surface of the optical element included inthe post-deflection optical system is configured of a diffractionoptical device.
 8. A method of manufacturing of an optical beam scanningapparatus comprising a light source for emitting one or plural luminousfluxes, a pre-deflection optical system to form a luminous flux emittedfrom the light source to image the luminous flux as a line image in aprescribed direction corresponding to a main scanning direction, ascanning unit configured to scan the imaged luminous flux by thepre-deflection optical system against a scanning subject, and apost-deflection optical system to image the luminous flux scanned by thescanning unit on the scanning subject, in which a width of the luminousflux made incident on the scanning unit from the pre-deflection opticalsystem is wider than a width of one reflecting surface forming thescanning unit and an angle formed by an optical axis of the luminousflux made incident on the scanning unit and an optical axis of thepost-deflection optical system is satisfied with a prescribed condition,wherein after allowing a resin to flow into a molding die through a gateopening for allowing a resin to flow into the molding die, which isprovided in advance to the molding die, the flown-in resin is moldedinto a prescribed shape to manufacture an optical element; and inarranging at least one optical element in the post-deflection opticalsystem, the optical element is arranged such that a side correspondingto a side of the gate opening through which the resin flows is a lightincidence side where the luminous flux enters into the scanning unit. 9.An image forming apparatus provided with an optical beam scanningapparatus comprising: a light source for emitting one or plural luminousfluxes, a pre-deflection optical system to form a luminous flux emittedfrom the light source to image the luminous flux as a line image in aprescribed direction corresponding to a main scanning direction, ascanning unit configured to scan the imaged luminous flux by thepre-deflection optical system against a scanning subject, and apost-deflection optical system to image the luminous flux scanned by thescanning unit on the scanning subject, in which a width of the luminousflux made incident on the scanning unit from the pre-deflection opticalsystem is wider than a width of one reflecting surface forming thescanning unit and an angle formed by an optical axis of the luminousflux made incident on the scanning unit and an optical axis of thepost-deflection optical system is satisfied with a prescribed condition,wherein the post-deflection optical system includes at least one opticalelement configured by allowing a resin to flow into a molding diethrough a gate opening provided in advance to the molding die and thenmolding the resin into a prescribed shape; and in the optical element, aside corresponding to a side of the gate opening through which the resinflows is provided to a light incidence side where the luminous fluxenters into the scanning unit.
 10. The image forming apparatus accordingto claim 9, wherein the optical element is a lens.
 11. The image formingapparatus according to claim 9, wherein the optical element isconfigured of a single lens.
 12. The image forming apparatus accordingto claim 9, wherein the post-deflection optical system includes pluraloptical elements configured by allowing the resin to flow into themolding die through the gate opening and then molding the resin into aprescribed shape; and with respect to at least one optical element ofthe plural optical elements, in the optical element, a sidecorresponding to a side of the gate opening through which the resinflows is provided in a light incidence side where the luminous fluxenters into the scanning unit.
 13. The image forming apparatus accordingto claim 12, wherein with respect to all of the optical elements of theplural optical elements, in the optical element, a side corresponding toa side of the gate opening through which the resin flows is provided ina light incidence side where the luminous flux enters into the scanningunit.
 14. The image forming apparatus according to claim 9, wherein inthe optical element, a gate cut part of the optical element is includedin a side corresponding to the side of the gate opening through whichthe resin flows.
 15. The image forming apparatus according to claim 9,wherein at least one surface of the optical element included in thepost-deflection optical system is configured of a diffraction opticaldevice.
 16. A method of manufacturing of an image forming apparatusprovided with an optical beam scanning apparatus comprising: a lightsource for emitting one or plural luminous fluxes, a pre-deflectionoptical system to form a luminous flux emitted from the light source toimage the luminous flux as a line image in a prescribed directioncorresponding to a main scanning direction, a scanning unit configuredto scan the imaged luminous flux by the pre-deflection optical systemagainst a scanning subject, and a post-deflection optical system toimage the luminous flux scanned by the scanning unit on the scanningsubject, in which a width of the luminous flux made incident on thescanning unit from the pre-deflection optical system is wider than awidth of one reflecting surface forming the scanning unit and an angleformed by an optical axis of the luminous flux made incident on thescanning unit and an optical axis of the post-deflection optical systemis satisfied with a prescribed condition, wherein after allowing a resinto flow into a molding die through a gate opening for allowing a resinto flow into the molding die, which is provided in advance to themolding die, the flown-in resin is molded into a prescribed shape tomanufacture an optical element; and in arranging at least one opticalelement in the post-deflection optical system, the optical element isarranged such that a side corresponding to a side of the gate openingthrough which the resin flows is a light incidence side where theluminous flux enters into the scanning unit. Image Page 7